Printing on comestible products

ABSTRACT

A color image may be applied onto a substantially planar carrier, and the carrier may be deformed to form a non-planar relief mold of a three-dimensional image, including deforming the color image whereby the deformed color image is proportionate relative to, i.e., is in register with, the three-dimensional image. A comestible material, e.g., chocolate, may be deposited into the relief mold to substantially overlie the color image. The comestible material may be removed from the relief mold, with the color image applied thereto. In one implementation, the color image may be applied to the substantially planar carrier by screen printing one or more colors forming the color image onto the carrier using an edible ink composition.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No.10/758,236 filed on Jan. 15, 2004 now U.S. Pat. No. 7,144,594, byWoodhouse et al., which claims priority to Great Britain applicationnumber 0300908.1 filed on Jan. 15, 2003. The entire contents of theseapplications are incorporated herein by reference.

TECHNICAL FIELD

This invention relates to techniques and compositions for applying adecorative image to a comestible product.

BACKGROUND

Decorative images are frequently applied to confections and foodarticles (i.e., comestible products), such as cakes, pastries, icecream, and baked goods. Frequently, decorative images are borne on anedible substrate that is transferred to a surface of a food article tobe decorated. The edible substrates are often thin, fragile layers ofstarch-based edible material. Such materials facilitate transfer of thedecorative image to the surface of the food article without detractingfrom the texture or appearance of the original food article. Preferably,the edible substrates may be relatively durable so as to withstand theprinting and transferring processes.

Edible substrates may be deposited onto a releasable backing paper orfilm to provide support throughout the printing process and tofacilitate handling of the edible substrate. After the edible substrateis properly transferred to the food article, the backing paper may bepeeled away to show the decorative image on the surface of the foodarticle.

Edible substrates can be formed by depositing an edible formulation on abacking paper using “screen printing” process. In such processes, ascreen fixture is positioned over the surface of the backing paper andthe edible material is manually forced through a screen mesh using asqueegee or other similar device. The screen printing process can beused to apply a decorative image to a planar substrate for transfer to aplanar target surface, such as the flat surface of a cake.

Applying a decorative image to a non-planar (i.e., three-dimensional)target surface is typically more laborious and time-consuming.Transferring a decorative image from release layer (i.e., a 2D surface)onto a non-planar surface (i.e., a 3D surface) can result in skewing ordistortion of the decorative image, for example, due to raised areas onthe non-planar surface distorting the originally 2D decorative image.

Accordingly, conventional techniques for applying a decorative image toa non-planar surface include hand painting a multi-colored image onto arelief mold surface using a pre-tempered colored chocolate, andthereafter filling the mold with a comestible material, such aschocolate, and, upon cooling, demolding the chocolate with themulti-colored image applied. The hand-painting technique is notconducive to mass production, due to the time and expense involved.

SUMMARY

In various implementations, a method for applying a color image to anon-planar comestible may include applying a disproportionate colorimage onto a substantially planar carrier and deforming the carrier toform a non-planar relief mold of a three-dimensional image, whereby thedeformed color image is proportionate relative to the three-dimensionalimage. A comestible material, such as chocolate or a chocolate compound,may be deposited into the relief mold to substantially overlie the colorimage. The comestible material may be removed from the relief mold, withthe color image applied thereto. In one implementation, thedisproportionate color image may be applied to the substantially planarcarrier by screen printing one or more colors forming the color imageonto the carrier using an edible ink composition.

Edible ink compositions can include one or more of each of thefollowing: a viscosity controller, a film forming compound, anemulsifier, and a food grade colorant. Optional ingredients include oneor more plasticizers or humectants. Edible ink compositions aregenerally prepared as aqueous solutions, e.g., for application to acarrier.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG 1A is a flowchart showing a process for creating a 3D model.

FIGS. 1B and 1C are flowcharts showing a process for applying a colorimage to a 3D comestible product.

FIG. 2 shows a 2D artwork representing a 3D decorative image.

FIG. 3A shows an outline of an image printed onto the surface of asubstrate.

FIG. 3B show a 3D model affixed to the surface of the substrate of FIG.3A.

FIG. 4A shows a carrier aligned in a screen printing machine.

FIG. 4B shows the carrier of FIG. 4A with a mirror image of the artworkof FIG. 2 printed thereon.

FIG. 5 shows the carrier of FIG. 4B aligned in a vacuum forming machine.

FIG. 6A shows the carrier of FIG. 4B impressed with the 3D model of FIG.3B.

FIG. 6B shows the reverse side of the carrier of FIG. 6A.

FIG. 7A shows a disproportionate version of the 2D artwork of FIG. 2.

FIG. 7B shows the disproportionate 2D artwork of FIG. 7A overlaying the2D artwork of FIG. 2.

FIG. 8 shows a colored, disproportionate 2D artwork.

FIG. 9 shows a 3D comestible product adorning a bakery item.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENT

A technique for applying a decorative image to a three-dimensionalsurface of a comestible product may include applying a disproportionateimage to a substantially planar carrier and deforming the carrier into athree-dimensional relief mold, such that upon being deformed, thedecorative image is proportionate to (i.e., aligns with) thethree-dimensional (3D) surface. The deformed decorative image can thenbe applied to a three-dimensional target surface. The end product may bea comestible product, for example, a chocolate figurine or cakedecoration, having at least one substantially non-planar surface, with adecorative image of one or more colors applied to the non-planar surfaceof the comestible product. For example, an edible chocolate figurine canbe shaped as a popular cartoon character and a three-dimensional imagedepicting the character can be applied to a surface of the figurine.

An iterative process described below can be used to create an image thatis suitably disproportionate to an original 2D artwork, such that whenapplied to a carrier and deformed into a 3D relief mold, the imagealigns with the corresponding 3D impression formed in the carrier (i.e.,the relief mold). Referring to FIG. 1A, a process 100 for creating a 3Dmodel representative of a comestible product to which a multi-coloreddecorative image is to be applied is shown.

In a first step, a two-dimensional (2D) artwork is designed illustratinga two-dimensional representation of the three-dimensional decorativeimage to be applied to the three-dimensional surface of the comestibleproduct (step 102). For example, referring to FIG. 2, a 2D artwork 200of an image of a cartoon man (the “Cartoon Man”) is shown. A 3Dtemporary model of the 2D artwork, i.e., a 3D Cartoon Man, is preparedbased on the 2D artwork (step 104). The temporary model may be handsculpted from a pliable material that can be hardened, such asplasticine or modeling wax. Alternatively, the temporary model can bemachined, for example, using a CNC (computer numerical control) machineor pantograph, and using a metal or plastic material.

A 3D temporary relief mold is created from the temporary model, forexample, by pouring a liquid, silicon rubber over the temporary modeland allowing the rubber to harden (step 106). The rubber can then beseparated from the temporary model, thereby forming the 3D temporaryrelief mold. A food grade material that can be used to form a solid,more durable permanent model, such as resin, brass, aluminum orstainless steel, is poured in a liquid form into the temporary reliefmold (step 108). The material is allowed to solidify and is removed fromthe temporary relief mold, resulting in a permanent model representativeof the comestible product to which a multi-colored decorative image isto be applied (step 110).

FIG. 1B is a flowchart showing a process 111 for creating an adjusted 2Dartwork that is suitably disproportionate to the original 2D artwork200, such that when applied to a carrier and deformed into a 3D reliefmold, the image represented by the adjusted 2D artwork aligns with thecorresponding 3D impression formed in the carrier (i.e., the reliefmold). Referring to FIG. 3B, in a first step, the permanent model 310(which can be formed as per FIG. 1A) is affixed to a substrate 305 thatwill be used during a vacuum forming process. Optionally, beforeaffixing the permanent model to the substrate, an outline 300 of thedecorative image (i.e., a black outline without any colored regions) canbe applied to the substrate 305, as shown in FIG. 3A, and the permanentmodel 310 then aligned to the outline 300 and mounted onto the substrate305. This step can be particularly useful for commercial mass productionof a comestible product, when multiple permanent models may be createdand affixed to a single substrate, such that multiple relief molds canbe simultaneously created. In such an application, printingcorresponding multiple outlines of the image onto the substrate beforeaffixing the multiple permanent models facilitates a later step of aligna carrier to the models.

The permanent model 310 can be affixed to the substrate 305 using anadhesive, screws or other convenient means. The substrate 305 can beformed from a perforated stainless steel, for example, such that duringa vacuum forming process air can be extracted through the perforations.Optionally, holes can be drilled through the permanent model 310, whichholes align with holes or perforations in the substrate 305, such thatduring a vacuum forming process air can be extracted through the holes,which can be particularly useful in detailed regions of the permanentmodel 310.

The outline 300 can be applied to the substrate 305 using any convenientprinting technique, for example, screen printing. The original 2Dartwork 200 (FIG. 2) can be used to prepare a screen, and usingconventional screen printing techniques, the outline 300 is printed ontothe substrate 305.

A food grade substrate is used as a carrier for an edible, decorativeimage that will be applied to the three-dimensional comestible. In oneimplementation, the substrate is a thermoplastic sheet made of, forexample, virgin grade polyvinyl chloride, polypropylene, polycarbonate,acrylic or high impact polystyrene. The carrier may be transparent oropaque, although transparency can assist certain steps in the process asnoted below. In one implementation, the carrier has a thickness in therange of approximately 100-400 microns, and can be, for example, 275microns thick.

A mirror image outline of the original 2D artwork 200 is printed ontothe carrier (step 116). In one implementation, the original 2D artwork200 is used to create a screen of the mirror image outline and themirror image outline is screen printed onto the carrier. Referring toFIG. 4A, the carrier 400 is shown positioned within a screen printingmachine 405. The carrier 400 can be aligned to a lay edge 410 (i.e., aguide) along a width-wise side 411 of the carrier 400 and a second layedge 415 along a length-wise side 414 of the carrier. The lay edges 410,415 can be flat steel plates to guide or stop a sheet of material atsubstantially the same place each time a sheet is positioned within themachine. The mirror image screen is then used with the screen printingmachine 405 to print the mirror image outline 420 onto the carrier 400,as depicted in FIG. 4B.

In one implementation, the blank carrier 400 can be aligned within thescreen printing machine 405 as follows, such that the mirror imageoutline is printed at the appropriate location on the carrier 400 sowhen the printed carrier 400 is placed within a vacuum forming machine,the mirror image outline generally aligns with the permanent model 310(although other techniques to ensure alignment can be used). Using atransparent carrier 400, an operator places the blank carrier 400 facedown over the permanent model 310 affixed to the plate 305 and handmarks registration points onto the backside of the blank carrier 400.For example, the operator can trace an outline of the permanent model310 or trace certain features (e.g., the eyes and mouth of the CartoonMan) onto the carrier 400 using a felt tip pen (the tracings being theregistration points). When the carrier 400 is then placed (face-up)within the screen printing machine 405 and the screen of the mirrorimage outline is positioned over the carrier 400, the position of thecarrier 400 can be adjusted until the mirror image outline on the screenis aligned to the registration points. That is, when the carrier 400 isaligned to the screen, the registration points marked onto thetransparent carrier 400 will be visible to an operator through themirror image outline on the screen. The mirror image outline willthereby be printed in the appropriate region on the carrier 400, suchthat when the printed carrier 400 is placed within the vacuum formingmachine within the lay edges (described below), the permanent model 310will contact the printed carrier 400 at a location coinciding with themirror image outline 420.

Referring to FIG. 5 and again to FIG. 1B, the printed carrier 400 ispositioned face down (i.e., printed side down) in a vacuum formingmachine 500 (step 118). The printed carrier 400 is aligned to a lay edge505 along a width-wise side of the carrier 400 and to a second lay edge510 along a length-wise side of the carrier. The printed carrier 400 canbe warmed to increase pliability, for example, to a temperature in therange of approximately 60 to 80 degrees Celsius, such as 75 degreesCelsius if using a polyvinyl chloride material to form the carrier 400.A tray (not shown) upon which the plate 305 and permanent model 310 arepositioned is raised up to meet the printed carrier 400 and a vacuum isapplied to deform the printed carrier 400 to the permanent model 310(step 120). The carrier 400 once separated from the permanent model 310is impressed with the 3D representation of the decorative image, asshown in FIGS. 6A and 6B, and thereby forms a 3D relief mold 600.

One example of a vacuum forming machine is a vacuum forming unitavailable from Illig UK Ltd. of Bedfordshire, United Kingdom. The moldtool (i.e., the plate 305 with the permanent model 310 affixed), in maleor female format, used in the vacuum forming machine can be made fromaluminum, aluminum resin, brass, copper or magnesium and can be coatedwith a heat resistant, non-stick material, such as TEFLON™, Xylan or thelike.

Referring to FIG. 6A and again to FIG. 1B, the mirror image outline 620of the original 2D artwork 200 that was printed onto the carrier 400 isdeformed during the vacuum forming process, by virtue of the carrierbeing stretched to form a 3D relief mold. The deformed outline 620 isexamined to determine whether the outline aligns with the 3D impression600 of the decorative image now formed in the carrier (step 122). If thedeformed outline 620 does not align with the 3D impression 600 (“No”branch of step 122), then the amount by which the outline should bemoved when printed onto the carrier before deformation—so that upondeformation the outline will align with the 3D impression 600—ismeasured (step 124). Deformation generally occurs due to the height ordepth of the 3D impression.

In FIG. 6A the mirror image outline 620, which is shown as a solid line,and the boundary of the 3D impression 600, which is shown as a dottedline, appear to align in some regions and are not aligned in others. Forexample, at the top of the Cartoon Man's head, the outline 620 is adistance x from the boundary of the 3D impression 600 corresponding tothe top of the Cartoon Man's head. Distances of misalignment, such asdistance x, are measured where the outline 620 does not align to acorresponding feature formed in or by the 3D impression 600.

An example of a disproportionate 2D artwork 700 is shown in FIG. 7A, andis shown overlaying the original 2D artwork 200 represented as a dottedline in FIG. 7B, to illustrate the adjustments made to the original 2Dartwork 200. For example, the girth in the stomach region 710 of theCartoon Man results in more deformation in the stomach region 710 thanin less protruding areas of the Cartoon Man, such as the hands 720.Accordingly, the deformed outline is less likely to align to the 3Dimpression in the stomach region 710 due to the outlining deformingconsiderably in this region.

Referring again to FIG. 2, the original 2D artwork 200 is adjusted basedon the measurements to create an adjusted 2D artwork (step 126). Forexample, the Cartoon Man's head can be adjusted based on the measurementof the distance x between the outline 620 and the 3D impression 600. Theadjusted 2D artwork is disproportionate to the original 2D artwork 200,SO that when an outline based on the adjusted 2D artwork is applied tothe carrier and deformed to create a 3D relief mold, the outline alignswith the 3D impression formed in the carrier (i.e., the 3D relief mold).That is, for example, at the top of the Cartoon Man's head the printedoutline based on the adjusted 2D artwork will align with the boundary ofthe 3D impression, as compared to the obvious misalignment depicted inFIG. 6A. Typically, one or more additional iterations of the processdescribed above, in particular steps 116-126 are required to finallyadjust the original 2D artwork 200 such that when deformed, thedecorative image aligns to the 3D relief mold.

For example, the adjusted 2D artwork created at step 126 is used tocreate a mirror image outline of the adjusted 2D artwork that is thenprinted onto a blank carrier (2^(nd) iteration of step 116). The printedcarrier is positioned face down in a vacuum forming machine (2^(nd)iteration of step 118) and is vacuum formed to the permanent model(2^(nd) iteration of step 120). An operator then examines the deformedadjusted outline to determine whether or not the outline aligns with the3D impression formed in the carrier (2^(nd) iteration of step 122). Ifthe deformed outline still does not align to the 3D impression (“No”branch of decision step 122), then the operator measures the movement ofthe adjusted outline with respect to the 3D impression (2^(nd) iterationof step 124) and adjusts the artwork a second time based on themeasurements (2^(nd) iteration of step 126).

If the deformed outline does align to the 3D impression (“Yes” branch ofdecision step 122), then the adjusted artwork that was used to createthe deformed outline has been adjusted sufficiently from the original 2Dartwork 200, such that when deformed the decorative image aligns to the3D relief mold. Referring to FIG. 1C, the adjusted artwork is used toprint a corresponding colored decorative image onto a carrier (step130). For example, if a screen printing process is used to print ontothe carrier, then a multi-step process may be used to print the colorimage, for example, if multiple colors are required to create thecolored image.

FIG. 8 shows the Cartoon Man 800 printed in color on a carrier 805. Thetargets 810 shown in the corners of the carrier 805 can be used to alignthe screens used in a multi-step process to the carrier 805, such thatthe colored image printed onto the carrier 805 with respect to eachscreen is in alignment. Alternative methods of printing can be used,such as offset printing, thermal transfer, ink jetting, and the like.The colored decorative image can be printed using an edible inkcomposition, such as the composition described below.

The color printed carrier 805 is vacuum formed to the permanent model310 (step 132), thereby creating a 3D relief mold with the coloreddecorative image 800 adhered to the mold surface. If a male mold tool isused, such as the permanent model described in the illustrative exampleabove, then the colored image is adhered to an interior surface of themold. Alternatively, a female (i.e., concave) mold tool can be used, inwhich case the colored image is adhered to an exterior surface of themold. The color is applied using an edible ink mixture, describedfurther below.

The relief mold can either be filled with an edible material (step 134),for example, a jelly, fudge, chocolate or a chocolate compound, or therelief mold can be stored for later use. To fill the relief mold with anedible material, the carrier 805 is trimmed, if necessary, to fit withina filling machine. Suitable machines are available from Knobel inSwitzerland. The jelly, fudge, chocolate or chocolate compound is meltedand deposited into the relief mold. For example, chocolate can be meltedto a temperature of approximately 35-50° Celsius. The filled relief moldis cooled, for example, by passing the filled relief mold through acooling tunnel. Suitable cooling tunnels are available from Sollich ofPeterborough, United Kingdom. In one implementation, a relief moldfilled with chocolate or a chocolate compound is cooled to 5° C. forapproximately 15 minutes. Once the edible material has cooled to atemperature at which the edible material is self-supporting, the ediblematerial is removed from the mold (step 136) with the color imageadhering to a surface of the edible material.

The demolded comestible product may be an edible chocolate figurine ormay be used as a cake adornment, for example. FIG. 9 shows a finished 3Dcomestible product 900 with the Cartoon Man decorative image applied toa non-planar surface of the product 900, which product 900 is used toadorn the top of a cake 905.

Once a suitably adjusted 2D artwork has been arrived at using thetechniques described above in reference to FIG. 1B, multiple reliefmolds can be produced at the same time for mass producing the desiredcomestible product. Multiple decorative images can be applied to asingle carrier, and a corresponding number of multiple permanent modelsaffixed to a single substrate. The carrier can then be vacuum formed tothe substrate, thereby forming multiple relief molds from the carrier.The carrier can be cut to separate the multiple relief molds.

In one implementation, an empty relief mold can be stored for at leastsix months before being filled with an edible material. An empty reliefmold can be stored at ambient temperature in a sealed bag or other suchpackaging providing a good moisture vapor barrier. The edible materialcan be stored in the mold for at least 18 months before being demolded.A filled mold can be stored in chilled conditions, for example, at atemperature of approximately 0 to 10° C., to maintain freshness.

Exemplary packaging materials for packaging an empty or filled mold caninclude polypropylene films, polyester films such as MYLAR® (availablefrom E.I. du Pont de Nemours and Company of Wilmington, Del.), foils(e.g., aluminum) and the like, and may be packed in a sturdy corrugatedbox to prevent damage.

In one implementation, a comestible product may be formed from two ormore different portions. For example, referring to the Cartoon Man cakeadornment 900 shown in FIG. 9, in the process described above, theCartoon Man cake adornment 900 was formed from a single relief mold as aone-piece comestible product. However, in an alternative embodiment, theCartoon Man cake adornment 900 can be formed from multiple pieces, suchas a separate piece for the head, separate pieces for the arms andseparate pieces for the legs. That is, five separate comestible productscan be formed and then assembled together on top of the cake 905 to formthe Cartoon Man cake adornment 900. Each separate comestible product isformed separately using the techniques described above in reference tothe Cartoon Man (as a whole). This multi-step process can be preferredwhen creating fragile comestible products that may break, for example,at points of weakness, such as where the arm attaches to the body, orthe like.

Edible Ink Compositions

Edible ink compositions described herein can be screen printed in afour-color process, for example, and are easily transferable from formedplastic molds and carriers to a comestible product. An edible inkcomposition can include one or more of each of the following: aviscosity controller, a film forming compound; an emulsifier; and a foodgrade colorant. Optional ingredients can include one or moreplasticizers or humectants. For application to a carrier, an edible inkcomposition is typically prepared as an aqueous solution.

Viscosity Controllers

One or more viscosity controllers can be used to provide structure andviscosity to an edible ink composition, e.g., to facilitate applicationto a carrier. Examples include various food grade starches andsweeteners. Starches in unrefined, refined, unmodified or modified formcan be used. Exemplary starches include maize (corn), potato, wheat, andtapioca starch. Exemplary sweeteners include glucose, lactose, dextrose,fondant icing sugar, and icing sugar.

The total amount of viscosity controllers can range from about 65% toabout 80% by weight of an aqueous edible ink composition, or any valuetherebetween (e.g., 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78,79% by weight). In some embodiments, the total amount of viscositycontrollers can range from about 70% to about 75% by weight of anaqueous edible ink composition, or any value therebetween. In certainembodiments, the total amount of viscosity controllers will range fromabout 72% to about 74% by weight of an aqueous edible ink composition.For example, fondant icing sugar can be used at about 73% by weight.

Starches and sweeteners for use as viscosity controllers can bepurchased commercially from a variety of sources, e.g., Penford Foods,Englewood CO.

Film Forming Compounds, Plasticizers, and Humectants

One or more film forming compounds can be used to provide bendability,flexibility, and peelability to an edible ink composition, e.g., tofacilitate its removal from a carrier and transfer to a comestibleproduct. Exemplary film forming compounds includehydroxypropylmethylcellulose and methylcellulose. Gum compounds can alsobe used as film forming compounds. For example, guar, acacia, or arabicgums can be used as a film forming compound.

One or more film forming compounds can be included in an amount rangingfrom about 0.6% to about 4% by weight of an aqueous edible inkcomposition, or any value therebetween (e.g., 0.8%, 0.9%, 1.0%, 1.2%,1.4%, 1.6%, 1.8%, 2%, 2.2%, 2.4%, 2.6%, 2.8%, 3%, 3.2%, 3.4%, 3.6%, or3.8%). In some embodiments, one or more film forming compounds can beincluded in an amount ranging from about 0.8% to about 1.4% by weight ofan aqueous edible ink composition, or any value therebetween (e.g.,0.9%, 1%, 1.1%, 1.2%, or 1.3%). For example,hydroxypropylmethylcellulose can be included in an amount of about 0.8%by weight.

In some embodiments, one or more plasticizers and/or humectants are alsoincluded in an aqueous edible ink composition. Plasticizers and/orhumectants can be used to retain moisture and impart flexibility. One ormore humectants or plasticizers, or both, can be included in a totalamount from about 0.03% to about 0.4% by weight of an aqueous edible inkcomposition, or any value therebetween (e.g., 0.04, 0.05, 0.06, 0.07,0.08, 0.1, 0.12, 0.15, 0.18, 0.2, 0.22, 0.25, 0.28, 0.3, 0.32, 0.35,0.38%). A typical plasticizer for use in a composition described hereinis propylene glycol; a typical humectant is glycerine. For example, insome embodiments, propylene glycol is included in an amount of about0.06% by weight of an aqueous edible ink composition.

Emulsifiers

An edible ink composition can include one or more emulsifers. Anemulsifier can help to ensure homogeneity of an edible ink compositionand to maintain the clarity of an image applied to a comestible.Suitable emulsifiers include, for example, lecithin, polyglycerolpolyricinoleate, acetic esters of monoglycerides, polyoxyethylenesorbitan monostearate (e.g. a commercially available product known asPOLYSORBATE 60, CRILLET, CRILLET VEG A, TWEEN, or TWEEN 60), andcombinations thereof.

The choice of emulsifier can be influenced by the nature of thecomestible to which the colored decoration is to be applied. Forexample, for chocolate comestibles, lecithin may be useful, whilePOLYSORBATE 60 may be used for sugar-based confections, such as hardcandies or fudge. In other embodiments, a mixture of emulsifiers can beused. A useful emulsifier mixture can include lecithin and POLYSORBATE60.

The total amount of emulsifiers in an aqueous edible ink composition canrange from about 1% by weight to about 12% by weight, or any valuetherebetween (e.g., 1.2, 1.5, 2, 2.2, 2.5, 2.6, 2.8, 2.9, 3, 3.2, 3.5,3.8, 4, 4.2, 4.5, 4.8, 5, 5.2, 5.5., 5.8, 6, 6.2, 6.5, 6.8, 7, 7.2, 7.5,7.8, 8, 8.2, 8.5, 8.8, 9, 9.2, 9.5, 9.8, 10, 10.2, 10.5, 10.8, 11, 11.2,11.5, or 11.8%). For example, a mixture of lecithin and POLYSORBATE 60can be used, where the lecithin ranges from about 3% to about 7% byweight of an aqueous edible ink composition, and the POLYSORBATE 60ranges from about 0.5% to about 5% by weight of an aqueous edible inkcomposition. In one embodiment, lecithin is used in an amount of about5.8% and POLYSORBATE 60 is used in an amount of about 2.9%.

Food Grade Colorant

An aqueous edible ink composition can include one or more food gradecolorants. As used herein, colorants include color enhancing agents andwhitening or opacifying agents. Suitable colorants can be, for example,whiteners, colorants, inks, dyes, or pigments. Any known colorantapproved for human consumption can be used, including, for example,carmoisine, quinoline, ponceau 4R, blue 1, vegetable carbon, blue V,blue 2, and FD&C pigments such as yellow 5, red 3, red 40, blue 1, andblue 2. Additional useful examples include powdered inks, e.g., E100,E102, E104, E110, E120, E122, E124, E127, E129, E131, E132, E133, E140,E141, E153, 160, E161(b), E163, E170, and E171. Typically, a food gradecolorant for use herein is soluble in aqueous solutions.

A colorant, e.g., a powdered ink, is added in an amount quantum satis,or an amount necessary to achieve the desired color and intensityrequired for a particular colored decoration. For example, a powderedink may be used at a pigment level between 5% and 30% of the powderedink. Typically, a colorant such as a powdered ink is added in an amountof about 0.01% to about 0.4% by weight of an aqueous edible inkcomposition, or any value therebetween (e.g., 0.02, 0.04, 0.06, 0.08,0.1, 0.12, 0.14, 0.16, 0.18, 0.2, 0.22, 0.24, 0.26, 0.28, 0.3, 0.32,0.34, 0.36, or 0.38%), although amounts outside these ranges can be usedin particular cases to achieve a desired color intensity.

Water

Water is typically included in an amount of from about 13% to about 25%by weight of an aqueous edible ink composition, or any valuetherebetween (e.g., about 14, 14.2, 14.5, 14.8, 15, 15.2, 15.5, 15.8,16, 16.2, 16.5, 16.7, 16.8, 17, 17.2, 17.5, 17.8, 18, 18.2, 18.5, 18.8,19, 19.2, 19.5, 19.8, 20, 20.2, 20.5, 20.8, 21, 21.2, 21.5, 21.8, 22,22.2, 22.5, 22.8, 23, 23.2, 23.5, 23.8, or 24% by weight). Certainembodiments have about 13% to about 18% water. For example, oneembodiment includes about 16.77% water. Once prepared, a colored aqueousedible ink composition can be used to achieve a four color process setor block print set, as described previously.

Exemplary Edible Ink Composition

Edible ink compositions are typically aqueous solutions and can beprepared using the previously described components at the previouslyindicated percentage by weight amounts. For example, a useful edible inkcomposition can be an aqueous edible ink composition comprising:

a) one or more viscosity controllers at about 73% to about 75% by weightof said aqueous edible ink composition;

b) one or more film forming compounds at about 0.5% to about 1.4% byweight of said aqueous edible ink composition;

c) one or more emulsifiers at about 5% to about 12% by weight of saidaqueous edible ink composition;

d) one or more plasticizers at about 0.03% to about 0.09% by weight ofsaid aqueous edible ink composition; and

e) water at about 12% to about 20% by weight of said aqueous edible inkcomposition.

In certain embodiments, the one or more viscosity controllers is fondanticing sugar; the one or more film forming compounds ishydroxypropylmethylcellulose; the one or more emulsifiers are lecithinand POLYSORBATE 60; and the one or more plasticizers is propyleneglycol. For example, in a specific embodiment, an aqueous edible inkcomposition can be prepared with the following ingredients (amounts byweight %):

% by Weight Dry Ingredients Fondant Icing (powdered) sugar 73.341Hydroxypropylmethylcellulose 0.8 Liquid Ingredients POLYSORBATE 60 2.94Propylene Glycol 0.06 Lecithin 5.88 Water 16.77

Methods for Preparing an Edible Ink Composition

An exemplary method for preparing an edible ink composition can includedissolving or dispersing one or more film forming compounds and optionalplasticizers and/or humectants in water using, for example, a high shearhand blender or Silverson Homogeniser. The aqueous mixture of filmforming compounds (with optional plasticizers or humectants) is referredto as a membrane mixture. One or more food grade colorants can then beadded and similarly dispersed in the aqueous membrane mixture. Theviscosity controller, e.g., fondant icing (powdered) sugar, is thenmixed with the membrane mixture in a similar manner. Finally, one ormore emulsifiers, e.g., lecithin and POLYSORBATE 60, are added and mixedin using, e.g., a Silverson Homogeniser, until a smooth liquid results.

The material used to fill the mold (e.g., chocolate or chocolatecompound) can be prepared accordingly to conventional techniques, andmay include some or all of the following ingredients:

a. icing or fondant icing (powdered) sugar;

b. lactose;

c. lecithin;

d. cocoa butter;

e. butterfat;

f. hydrogenated vegetable oil;

g. whey powders;

h. milk powders;

i. whole milk;

j. skim milk powder;

k. full cream milk;

1. gelatine;

m. citric acid;

n. starch/modified starch;

o. pectin; and/or

p. corn syrup

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.Accordingly, other embodiments are within the scope of the followingclaims.

1. A mold system for a comestible product, comprising: a threedimensional impression in a carrier to form a non-planar relief mold fora comestible material, the three dimensional impression corresponding toa three dimensional representation of a two dimensional image; and anedible ink image disposed on an interior surface of the threedimensional impression, the image being a disproportionate version ofthe two dimensional image such that the disproportionate image issubstantially in register with the three dimensional impression formedin the carrier.
 2. The mold system of claim 1, wherein the edible inkimage is disposed in the interior space of the three dimensionalimpression so as to receive the comestible material when the comestiblematerial is deposited into the non-planar relief mold.
 3. The moldsystem of claim 1, wherein the edible ink image is applied to a firstside of the carrier that becomes the interior surface of the threedimensional impression.
 4. The mold system of claim 1, wherein thecarrier has a thickness of less than about 400 microns.
 5. The moldsystem of claim 4, wherein the carrier has a thickness in the range ofabout 100 to about 400 microns.
 6. The mold system of claim 1, whereinthe edible ink image applied to an interior of the impression comprisesa multi-color image.
 7. The mold system of claim 6, wherein themulti-color image depicts a cartoon character.
 8. The mold system ofclaim 1, wherein the carrier comprises a thermoplastic sheet.
 9. Themold system of claim 8, wherein the thermoplastic sheet comprises amaterial selected from the group consisting of virgin grade polyvinylchloride, polypropylene, polycarbonate, acrylic and high impactpolystyrene.
 10. The mold system of claim 8, wherein the carrier issubstantially transparent.
 11. The mold system of claim 1, wherein theedible ink composition is an aqueous edible ink composition comprising:a) one or more viscosity controllers at about 65% to about 80% by weightof said aqueous edible ink composition; b) one or more film formingcompounds at about 0.6% to about 4% by weight of said aqueous inkcomposition; c) one or more emulsifiers at about 1% to about 12% byweight of said aqueous edible ink composition; d) a plasticizer at about0.03% to about 0.4% by weight; e) water at about 13% to about 25% byweight; and f) a powdered ink.
 12. The mold system of claim 1, whereinthe edible ink image comprises an edible ink composition including: a)about 73.3% by weight fondant icing sugar; b) about 0.8% by weighthydroxypropylmethylcellulose; c) about 2.9% by weight POLYSORBATE 60 andabout 5.9% by weight lecithin; d) about 0.06% propylene glycol; and e)about 16.8% water.
 13. The mold system of claim 1, further comprising acomestible material arranged in the three dimensional impression.
 14. Amold system for a comestible product, comprising: a three dimensionalimpression in a carrier to form a non-planar relief mold for acomestible material, the three dimensional impression corresponding to athree dimensional representation of a two dimensional image; and anedible ink image disposed on an interior surface of the threedimensional impression, the image being a disproportionate version ofthe two dimensional image such that the disproportionate image issubstantially in register with the three dimensional impression formedin the carrier, wherein the edible ink image is applied to a first sideof the carrier that becomes the interior surface of the threedimensional impression, wherein a boundary of the image applied to thecarrier is substantially in register with a boundary of the threedimensional impression formed in the carrier.
 15. The mold system ofclaim 14, wherein the edible ink image applied onto the carrier usingone or more colors of edible ink composition by a printing processselected from the group consisting of screen printing, offset printing,thermal transfer, and ink jetting.
 16. A mold system for a comestibleproduct, comprising: a three dimensional impression in a carrier to forma non-planar relief mold for a comestible material, the threedimensional impression corresponding to a three dimensionalrepresentation of a two dimensional image; an edible ink image layerdisposed on an interior surface of the three dimensional impression, theedible ink image layer being a disproportionate version of the twodimensional image such that the disproportionate image layer issubstantially in register with the three dimensional impression formedin the carrier; and a comestible material deposited in at least aportion of an interior space of the three dimensional impression tocontact the edible ink image layer.
 17. The mold system of claim 16,wherein the edible ink image layer is applied to a first side of thecarrier that becomes the interior surface of the three dimensionalimpression.
 18. The mold system of claim 17, wherein a boundary of theedible ink image layer applied to the carrier is substantially inregister with a boundary of the three dimensional impression formed inthe carrier.
 19. The mold system of claim 17, wherein the carrier has athickness in the range of about 100 to about 400 microns and comprises athermoplastic sheet selected from the group consisting of virgin gradepolyvinyl chloride, polypropylene, polycarbonate, acrylic and highimpact polystyrene.
 20. The mold system of claim 16, wherein thecomestible material is a jelly, fudge, chocolate, chocolate compound, orcombination thereof.
 21. The mold system of claim 16, wherein the edibleink image layer comprises an edible ink composition including: a) one ormore viscosity controllers at about 65% to about 80% by weight of saidaqueous edible ink composition; b) one or more film forming compounds atabout 0.6% to about 4% by weight of said aqueous ink composition; c) oneor more emulsifiers at about 1% to about 12% by weight of said aqueousedible ink composition; d) a plasticizer at about 0.03% to about 0.4% byweight; e) water at about 13% to about 25% by weight; and f) a powderedink.
 22. The mold system of claim 16, wherein the edible ink image layercomprises an edible ink composition including: a) about 73.3% by weightfondant icing sugar; b) about 0.8% by weighthydroxypropylmethylcellulose; c) about 2.9% by weight POLYSORBATE 60 andabout 5.9% by weight lecithin; d) about 0.06% propylene glycol; and e)about 16.8% water.
 23. A mold system for comestible products,comprising: a three dimensional impression formed in a carrier to definea non-planar relief mold for a comestible material, the threedimensional impression corresponding to a three dimensionalrepresentation of a two dimensional image, the carrier having athickness in the range of about 100 to about 400 microns and comprisinga thermoplastic sheet selected from the group consisting of virgin gradepolyvinyl chloride, polypropylene, polycarbonate, acrylic and highimpact polystyrene; and a multi-colored edible ink image screen printedto the carrier so as to be positioned on an interior surface of thethree dimensional impression, the image being a disproportionate versionof the two dimensional image, such that the disproportionate image issubstantially in register with the three dimensional impression formedin the carrier, wherein the edible ink image comprises an edible inkcomposition including: a) one or more viscosity controllers; b) one ormore film forming compounds; c) one or more emulsifiers; and d) one ormore food grade colorants.
 24. The mold system of claim 23, furthercomprising a comestible material arranged in the three dimensionalimpression.
 25. The mold system of claim 24, wherein the comestiblematerial is a jelly, fudge, chocolate, chocolate compound, orcombination thereof.